TOTAL QUALITY MANAGEMENT (TQM ), QUALITY CONTROL CIRCLES ( QCC ), SMALL GROUP ACTIVITIES ( SGA ), PROBLEM SOLVING TOOLS ( PST ), TOTAL EMPLOYEE INVOLVEMENT ( TEI ) MODEL,

1. TQM
&
QCC / SGA
R.Duraisamy M.S, EGMP (IIM-B)
MD- M/s Shrishti Consultants, Chennai
rd@shrishtibiz.com
+91 9445070511
www.shrishtibiz.com

2. Problems faced by Companies
•LPG (Liberalization,
Privatization &
Globalization)
•WTO (World of Threats &
Opportunities)
•Maintaining quality &
supplying ON TIME is not
a great thing.
•Resistance to change
•Lack of ownership /
responsibility
• Un satisfactory
performance on Productivity,
Quality, Cost, Delivery,
Morale & Safety –
(PQCDMS)
External Factors Internal Factors

3. TQC / TQM is an effort at continuous quality
improvement of all Processes, Products and
Services through TOTAL EMPLOYEE
INVOLVEMENT (TEI) that result in increasing
customer satisfaction, loyalty and improved
business results.
TQC / TQM

4. Customer
• A CUSTOMER is the most important visitor
on our premises.
• He is not dependent on us. We are
dependent on him.
• He is not an interruption of our work. He is
the purpose of it.
• He is not an outsider on our business. He
is a part of it.
• We are not doing him a favour by serving
him. He is doing us a favour by giving us
an opportunity to do so.
-Mahatma Gandhi

5. Kaizen Belief…
 Whatever we do can be continuously
improved- be it our working life or
personal life.
What
NEXT?

6. Concept & Implementation of
QCC / SGA

7. 70
20
10
0%
25%
50%
75%
100%
Employees of Orgn
Lower Middle Top
Mission, Strategic planning
Task Forces,
CFT, SIT, CIP
Suggestion,
SGA, QCC
Total Employee Involvement (TEI) Model

8. 1. Self development.
2. Mutual development.
3. Improvement in Productivity, Quality
4. Improvement in communication & Attitude
5. Reduction in waste & cost.
6. Problem solving opportunities.
7. Team building.
8. Links all levels of management towards success.
9. Get people more involved & Interested in work.
10. Improvement in participation.
11. Reduces absenteeism & grievances.
What we get from QCC activities

9. QCC is for
• Self and mutual development of the grass root
level employees
• Learning how to be systematic
• How to make use of the brain power for the
betterment
• Understanding the importance of data
• How to collect data, categorize, prioritize
• Finding out the inter relationship between data
• How to work as a team

10. We understood that by “BRAIN STORMING” any b
Task can be achieved..
Now there is no confusion in my process.
Muda of movement & fatigue is reduced to operato
I got an opportunity to identify my hidden potentia
We have understood the strength of PDCA cycle.
TKM
What we got thru SGA / QCC?

11. Job Satisfaction by Team Work
Computer skills improved
Operator fatigue reduced
House keeping improved
Recognition from co workers
Confidence level improved
WIL-Chennai
What we got thru SGA / QCC?

12. Acquired problem solvingAcquired problem solving
skillsskills
 Gained knowledge ofGained knowledge of
Ultra sonic welding processUltra sonic welding process
Gained Self confidenceGained Self confidence
Improved CommunicationImproved Communication
skillsskills
Learned to work in teamLearned to work in team AIB
What we got thru SGA / QCC?

13. What we got thru SGA / QCC?
• Recognition and self
esteem increased
• Individual knowledge
enhanced
• Presentation and
communication skill
improved
• Approach for problem
solving
• Team work and
opportunity to expose
Hidden skills
Got motivated to do more QCC projects
Mr.Siddaramappa
RADAR GRAPH
0
1
2
3
4
5
Communication
Recognition
Self esteem increased
Presentation Skill
Problem solving
Application of 7QC Tools
To expose Hidden skills
Team work
BEFORE AFTER
…… Together we learn, work and contribute KTTM

14. What we got thru SGA / QCC?
TKAP

15. 1. Establish a suitable atmosphere.
2. Obtain commitment from Top Management
3. Select the right people at the right area.
4. Select Objectives.
5. Expose people to the program.
6. Inform and communicate.
7. Keep the program voluntary.
8. Training is critical.
9. Start slowly, Grow slowly.
10. Be open and positive.
11. Monitor progress and changes
Steps to Start a QCC program

16. Forming QCC

17. QCC Structure

18. People are of different nature

19. ALIGNMENT THRU QCC / SGA

20. Training

21. 10 Problem Solving Tools (PST)
1. Flow Diagram
2. Brain Storming
3. Check sheet
4. Stratification
5. Pareto Diagram
6. Cause & Effect Diagram
7. Why-Why Analysis
8. Control Chart & Graphs
9. Scatter Diagram
10.Histogram

22. Brainstorming is a group participative technique.
It unlocks and discloses the untapped creative talents
and resources in people.
It is technique for generating the greatest possible
number of ideas.
Brainstorming

23. Check Sheet
• Simple data recording format for collecting data
Easily, efficiently and more systematically
Category Jan '15 Feb '15 Mar '15 Total
Rent 7000 7000 7000 21000
Grossories 2000 3000 2500 7500
Entertainment 600 900 1000 2500
Electricity 600 500 400 1500
School fee 700 700 700 2100
Cosmetics 600 900 600 2100
Medical 1000 400 300 1700
Others 3000 2000 2800 7800
Total 15500 15400 15300 46200
Expenditure Detail

24. • Used to analyse the problem by breaking it apart and examining
each piece separately.
•Stratification by itself does not solve problem, but it make it
possible to gain insight that will aid in the solution.
Mr Ashok
Door No.2 ,
32 nd Cross, 9 th Main,
4th Block, Jayanagar,
Bangalore,
Karnataka,
India
Level 1 Level II Level III Level IV Level V Level VI Level VII Level VIII
Tamil Nadu Mysore Shivajinagar 1st Block 1st Main 1st cross Door No.1
Karnataka Hassan Jayanagar 2nd Block 2nd Main 2nd cross Door No.2
Kerala Dharward Vijayanagar 3rd Block 3rd Main 3rd cross Door No.3
Andra Bangalore Indranagar 4th Block 4th Main 32nd cross Door No.4
etc. etc. etc. etc. 9th Main 33rd cross Door No.5
etc. etc. etc
India
Stratification

25. •Combines a column graph and a line graph.
•The Pareto analysis helps to identify the
VITAL FEW from the TRIVIAL MANY
Vilfredo Pareto, Italian Sociologist-
Uneven distribution of wealth.
Pareto of Expenditure
5500
3000
1400
600 550 425 330
46
71
83
88
92 96 98 100
0
3000
6000
9000
12000
Entertainm
ent
R
ent
G
rossories
S
choolfee
C
osm
etics
M
edical
Electricity
O
thers
Rs
0
25
50
75
100
Cum%
Trivial
Many
Vital
Few
Pareto Diagram

26. • Represent the relationship between an effect and its
causes.
•It is also called as, “Fishbone diagram” & “Ishikawa
Diagram”
Man Machine
Material Method
Cause Effect
Cause & Effect Diagram

27. Finding Root Cause with 5 Why
• 5 Why
– A way of peeling back
the problem until the
root cause is exposed
– A basic and effective
method
– Verifying each answer
along the way
5x
Ask
“Why!“
4x
Ask
“Why!“
3x
Ask
“Why!“
2x
ask
“Why!“
Root
Cause1x
ask
“Why!”

28. 5 Why Example
• Problem:
– Spindle not rotating
• Why?
– Bearing jammed
• Why?
– No lubrication.
• Why?
– Lubrication oil tank empty.
• Why?
– Operator not filled the oil.
• Why?
– Operator could not know the oil level.
• Why?
– Oil level indicator not visible.
• Conclusion:
– Make oil level indicator visible.
Ask “Why!”

29. Graph is a pictorial representation of data which is
easily understandable at a glance.
0
20
40
60
80
100
Nos
1s t Q tr 2nd
Q tr
3rd Q tr4th Q tr
Production trend
Produc t x Produc t Y
Production trend
0
20
40
60
80
100
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr
Pro d uct x Pro d uct Y
Production trend
0
50
100
1st Qtr
2nd Qtr
3rd Qtr
4th Qtr
Pro d uct x Pro d uct Y
Graph

30. A control chart is a graphical device to aid in process control.
It consist of a graph with a central line, “Upper Control
Limit” and “Lower Control Limit”.
Quality measured periodically is plotted on the chart
and status of control assessed.
Shaft dia (Spec 10 +/- 2mm)
13
10.2
109.8
9.5
10.410.5
10
7
9
11
13
1 2 3 4 5 6 7 8
Hour
mm
Actual
USL
LSL
UCL
LCL
Nominal
Control Charts

31. •Histogram is a form of column graph which displays the
distribution of values obtained whenever numerical data is
used.
•In a continuous production, it normally takes a bell shape.
Histogram for shaft dia (Spec 10 +1)
0
2
4
6
8
10
12
14
16
18
20
1 2 3 4 5 6 7 8 9 1 0 1 1
DIA
No.ofpeicess
10
10.5
11
LSL
USLNOMINAL
Histogram

32. A Scatter diagram shows relationship
between two variables. (E.g.: Hardness &
Wear) Electrode life detail
40
50
60
70
80
64 66 68 70 72 74 76
Hardne ss in HRB
Scatter Diagram

33. Example of Q.C.C Case Studies
 Reducing Rejections
 Reducing Cycle Time
 Reducing Consumables Cost
 Reducing Energy Cost
 Improving manufacturing process
 Erratic behaviour of machine

34. Example of Q.C.C Case Studies
 Elimination of mosquito menace in
the colony
 Raising blood donations
 Reducing accidents
 Improving security of goods in an
organisation
 Improving Environment of
Organisation

35. •Company top rank personnel attending QCC
presentations.
•Display of team member’s photos and project data
on bulletin Boards
•Completed projects published in the monthly
magazine
•Best QCC of the quarter award given in the
presence of all employees.
•Opportunities for some of the outstanding teams to
represent the company in STATE, NATIONAL &
INTERNATIONAL level.
Rewards / Recognition

36. Thank You
R.Duraisamy M.S, EGMP (IIM-B)
MD - M/s Shrishti Consultants, Chennai
rd@shrishtibiz.com
+91 9445070511
www.shrishtibiz.com